SuzukiSavage.com - One man engine insert

wombat Full Member Offline SuzukiSavage.com Rocks! Posts: 109	One man engine insert 06/12/12 at 06:26:17 Besides being verrrry careful and covering the frame with tape, etc., how can one person get an engine back into the frame (or frame back around the engine) without the scratching or chipping the frame's nice new paint job? I'm thinking of laying the engine on its side and dropping the frame over it. Any other ideas?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: One man engine insert Reply #1 - 06/12/12 at 06:43:28 I'm thinking of laying the engine on its side and dropping the frame over it. & youd be thinkin smart.. Mite be ahead to put the engine up on blocks & think thru how youl get bolts in once the frameis laid over it,
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: One man engine insert Reply #2 - 06/12/12 at 07:31:27 newly painted frame? can't be done
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Re: One man engine insert
Reply #3 - 06/12/12 at 07:52:17

If I were you I'd call one my heftier friends to come and lend a hand. I've re-installed both 2 and 4 cylinders, but always had a friend and a 2x4 and/or floor jack for leverage. Even then, it ain't easy! The first bolt is the critical "pivot bolt", and things get easier after that one. Even the shop manuals don't help much and usually just say something like "Step 3: re-install motor" LOL.

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justin_o_guy2

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Re: One man engine insert
Reply #4 - 06/12/12 at 08:23:14

I would put one side of the upper mount on the engine with A bolt poked thru & wired/ taped, whatever,, in place. Lay the frame on it & bolt the other half on. Align
engine/frame with lower bolt holes & stuff them in, no nuts needed. Stand it up & go to work,

You may be ahead with a piece of all thread cut in 2, so you can have your peg bolts in your hand & drive them thru, replacing the all thread, keeping the engine suported.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28619 Tucson Az Gender:	Re: One man engine insert Reply #5 - 06/12/12 at 08:38:08 I've done it solo,... but probably got a couple scratches... didn't notice... I did it with bike vertical,.. engine on a block to the left, straddled frame, lift, set, right arm through frame, wiggle, .. grunt... How do they manage at the factory?... Some kind of engine winch?......
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ralfyguy Serious Thumper Offline Posts: 932	Re: One man engine insert Reply #6 - 06/12/12 at 11:00:12 They may just put the transmission case in the frame and then put the cylinder together in the frame.
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Dave Sisk Full Member Offline SuzukiSavage.com Rocks! Posts: 163 Raleigh, NC Gender:	Re: One man engine insert Reply #7 - 06/12/12 at 11:18:02 Just curious...how much does the engine weigh? Dave
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: One man engine insert Reply #8 - 06/12/12 at 11:43:26 give or take a few... 100#
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28619 Tucson Az Gender:	Re: One man engine insert Reply #9 - 06/12/12 at 11:59:16 verslagen1 wrote on 06/12/12 at 11:43:26: give or take a few... 100# but,.. it feels like more... ...
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splash07 Serious Thumper Offline Posts: 911 Charleston, SC Gender:	Re: One man engine insert Reply #10 - 06/13/12 at 06:06:28 It can be done easily by laying the engine down and laying the frame over it, but I would suggest getting a buddy to help. Tape the frame and you should be fine.
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wombat

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Re: One man engine insert
Reply #11 - 06/13/12 at 10:58:45

It can be done, and I did it. Wrapped the newly-painted frame in tape and rags. Put the engine down on its right side. Removed the covers on the top of cylinder. Took off cable holder (it stuck up too high) for the decompression system. Lowered frame into place on the bottom of the engine and worked the top over the cylinder head. Tight fit with the front bolt from the left cylinder head cover, but finally got it.

splash07 wrote on 06/13/12 at 06:06:28:

It can be done easily by laying the engine down and laying the frame over it, but I would suggest getting a buddy to help. Tape the frame and you should be fine.

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Re: One man engine insert
Reply #12 - 06/13/12 at 11:20:38

Serowbot wrote on 06/12/12 at 08:38:08:

I've done it solo,... but probably got a couple scratches... didn't notice...
I did it with bike vertical,.. engine on a block to the left, straddled frame, lift, set, right arm through frame, wiggle, .. grunt...

How do they manage at the factory?... Some kind of engine winch?... Huh

...

Left, eh? I pulled it out on the right.

Spray the frame with plasti-dip!
When you're done just peel it off.

--Steve

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